Dados For Box Bottoms

I use 1/4” ply for my box bottoms but as you all know it is not 1/4”. What do you all use to cut the dados for this undersized ply? Mitered boxes vs. boxjointed where stopped dados are needed? The ply I get is not even consistently undersized! It ranges from 3/16 to 7/32 and I hate those rattling panels. Greg uses strips of rubber band shims which stop the rattle but I would like an option. Thanks for pondering this.

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

47 replies so far

andy they make those little rubber balls that they use for making cabinet panels, i have yet to use them as all of my boxes are solid wood and i plane them to the right size…but you might look up those rubber balls that they use for cabinet work…or, switch over to solid wood bottoms and make your own, i use 1/4 and sometimes i use 3/8..and since i make them, they come out just right..is that what your looking for…grizz

David, I’m trying to avoid using the 1/8” bit and multiple cuts if possible but your link to the undersized bits may be the answer I need. Thanks! I’m not too lazy to make multiple cuts but I take a risk every time I need to reposition my stop blocks for the stopped dados.

I have better luck making thicker bottoms and using 1/2” to 3/4” plywood. I generally buy 3 or 4 of the 4×8 sheets from the same stack, and stain one walnut, one cherry, and leave two maple. I cut them all in half lengthwise and then cut each half into about 8 inch wide strips 8 feet long. If I find I’m using a lot of one color I stain another half board and cut it into strips, or if I find I need an exceptionally wide bottom, I have material for that too.

The bottom line is that I have material for several months and can just carefully set up my dado for that one size and have a consistent fit. Since I have one saw that I dedicate to dado cuts and nothing else, I make one setup and I am good for several months of boxes.

I find that a little heavier bottom helps balance the open lids, makes a more sturdy box, and really makes very little difference in terms of the room inside the box. Plywood is stable enough that you can glue it on all four sides and stop that rattle you are talking about.

Andy, my solution is to rout 1/8” dadoes in the box, then use the table saw and cut a relief rabbet around the bottom material, adjusted to whatever depth gives the proper 1/8” remaining lip. A little trial and error with some scrap is necessary because, like you say, even the 1/4” material is not uniform. Obviously you leave the thicker portion to the bottom of the dado to allow for variance. This way you can cut stopped dadoes with no problem.